Development of New Kill Fluids with Minimum Sagging Problems for High Pressure Jilh Formation in Saudi Arabia

INTRODUCTION Barite sag is an unwanted variation in drilling fluid density after an extended period of static conditions. This problem is experienced frequently in Khuff and pre-Khuff gas wells in the Base Jilh Dolomite (BJD) formation. The Jilh formation is a dolomitic Middle Triassic tight zone that ranges from 8,000 ft to 10,000 ft true vertical depth (TVD) with abnormal saltwater pressure. Several factors add further complication to the problem of well control, such as uncertainty in predicting pore pressure, high temperature (300 °F), well deviation (leading to the Boycott settling phenomenon), drillpipe eccentricity and salt contamination of the drilling fluid. This high-pressure BJD formation requires a drilling fluid with a density up to 150 pcf. For high density fluids, achieving the right fluid formula with the right fluid rheology is difficult since excessive heat, dehydration and solids loading can deteriorate mud properties. The addition of weighting materials, such as barite (BaSO4) or hematite (Fe2O3), is needed to achieve the desired density to overbalance the well and avoid any possible flow from the formation; however, maintaining a high volume of solids content — of BaSO4 particles or any other material — in suspension is challenging, especially for extended periods of time. The separation of weighting material particles — usually BaSO4 — from the mud leads to undesirable density fluctuation as the drilling fluid is being circulated throughout the hole. This phenomenon, often referred as barite sag, may lead to serious well control incidents, stuck pipe, lost circulation and nonproductive time. Previous experience has shown that the barite sag phenomenon is attributed not only to mud-related problems but also to operation related practices1. Drillpipe eccentricity, stationary drillpipes, hole inclination and low annular velocities can dramatically increase barite sag2. Barite sag increases even faster as the hole angle increases to between 45° to 60°. This process was reported by Boycott in 1920, when he noticed that blood cells settled faster in inclined test tubes than in vertical tubes3.